4 Die Design

Chapter 5
Die Design
Die Design
Center of Pressure
Effect of center-of-pressure location on tool design
Die Design
Die Clearance
Die clearance is the space between the matting
members of a die set. Proper clearance between
cutting edges enables the fractures to meet and the
fractured portion of the sheared edge has a clean
appearance. For optimum finish of a cut edge,
proper clearance is necessary and is a function of
the kind, thickness and temper of the work
material.
Die Design
Die Clearance Calculation
Control of hole and blank sizes by clearance location.
Die Design
Die Clearance Calculation
Application of the die clearance for holes of irregular shape .
Die Design
Die Block General Design
Overall dimensions of the die block will be determined by
the minimum die wall thickness required for strength and
by the space needed for mounting screws and dowels and
for mounting the stripper plate.
Wall thickness requirements for strength will depend on
the thickness of the stock to be cut. Sharp corners in the
contour may lead to cracking in heat treatment, and so
require greater wall thickness at such points.
Die Design
Die Block Calculation
Rule of Thumb - Assuming a die block of tool steel its thickness
should be 20-mm. minimums for a blanking perimeter of 75-mm. or
less 25-mm. thick for perimeters between 75-mm. and 250-mm. and
32-mm. thick for larger perimeters. There should be a minimum of
32-mm. margins around the opening in the die block.
The die opening should be straight for a maximum of 3-mm; the
opening should then angle out at to 1 to the side (draft). The
straight sides provide for sharpening of the die; the tapered portion
enables the blanks to drop through without jamming.
Die Design
To secure the die to the die plate or die shoe, the following rules
provide sound construction:
On die blocks up to 175-mm square, use two M10 cap screws and
two dowels of dia. 10-mm.
On sections up to 200-mm. square, use three cap screws and two
dowels.
For blanking heavy stock, use cap screws and dowels of dia 12-mm.
diameter. Counter bore the cap screws 3.2-mm. deeper than usual,
to compensate for die sharpening.
Die Design
Die thickness is provisionally selected from Table shown. This
table takes into account the thickness of the stock and its
ultimate shear strength.
DIE THICKNESS PER TON OF PRESSURE
Stock
thicknes
s mm.
0.25
0.50
0.75
1.00
1.25
Die
thickness
cm. *
0.118
0.236
0.335
0.433
0.512
Stock
thickness
mm.
1.5
1.8
2.0
2.3
2.5
Die
thickness
cm. *
0.590
0.649
0.708
0.748
0.787
* For each ton per sq. cm. of ultimate shear strength.
Die Design
MINIMUM CRITICAL AREA VS. IMPACT PRESSURE
Impact
pressure,
tons
Area between
die opening
border,
sq. mm
20
50
75
100
322
645
968
1290
Critical distance A must not less than 1.5 to 2 times die thickness.
The critical area between the die hole and the die border must be checked
against minimum values in Table and die thickness B corrected if necessary.
Die Design
METHODS OF PUNCH SUPPORT
When cutting punch A is

sharpened, the same amount is
ground of spacer B to maintain
the relative distance.
If delicate punches must be

grouped closed in hardened
guide block with number of holes
sliding fitting in stripper plate.
Die Design
A slender piercing punch at left

shown in figure may be smaller
height than an adjacent large
punch.
If punches must protrude more

than 100 mm long fitted in punch
holder. An auxiliary plate may be
used to maintain stiffness.
Die Design
Flange width of the punch

should be greater than height to
provide stability for unguided
punches.
In a large punch, push-off pins

can prevent slugs from pulling up
and causing trouble.
Die Design
To avoid cracking a large

hardened punch or a punch
plate, do not press a small
punch directly into either of
these members. Instead, use a
soft plug or insert.
Long slotting punches should be

hollow ground so that dimension
A equals the metal thickness, so
as to put shear on the punch.
The ends should be flat for 1/8 in.
to avoid bending the stock.
Die Design
A quill is useful for supporting

pin punches.
A bushing in the stripper plate

can guide the quill for increased
punch support.
Die Design
Quills need not be limited to a

single punch. If prevented from
turning, they can be used for
pin punches on close centers.
Two quills are used for a

punch one to support
punch, the other to support
inner quill, when a stripper is
used.
bit
the
the
not
Die Design
A dowel can be used to prevent

rotation of the punches.
For high-speed dies, a flat on the

punch head is more positive.
Die Design
In
low-production
dies, a
setscrew is adequate to hold
the punch.
In low-production dies, a
setscrew is adequate to hold the
punch.
Die Design
Light drill-rod punches are

guided in the stripper plate to
prevent buckling.
Several punches can be set at

close center distances.
Die Design
STOCK STOPS
In its simplest form, a stock stop may be a pin or small block,
against which an edge of the previously blanked opening is
pushed after each stroke of the press. With sufficient clearance
in the stock channel, the stock is momentarily lifted by its
clinging to the punch, and is thus released from the stop. Figure
in the next slide shows an adjustable type of solid block stop
which can be moved along a support bar in increments up to 25
mm to allow various stock lengths to be cut off
Finger Stops
Die Design
STOCK STOPS
Starting Stop
Pin Stop
Die Design
STOCK STOPS
Trigger stops: (A) Top stock engagement; (B) Bottom stock engagement
Die Design
STOCK STOPS
A illustrates a pin stop suitable

for low-to medium-production
dies. When the ram ascends,
the strip clings to the punch, is
stripped, and then is fed until
the pin hits the edge of the hole.
shows the method of locating the

pin stop so that it bears against the
blank opening upon an angular
edge, so that the strip is crowded
against the backstop and accurate
piloting is obtained .
Automatic Stops
Die Design
STOCK STOPS
If no scrap is left between blanks,

as in a double-action blank anddraw die, a bent pin stop is
suitable. The sharpened point of
the stop faces the incoming strip,
when contact is made at the
opposite side of the hole.
A design in which combinations

stop and backup block locates the
strip and prevents deflection of the
cutoff punch of this two-station
die. The part, a flat spring, drops
to the punch holder and slides by
gravity to the rear of an inclined
press.
Automatic Stops
Die Design
STOCK STOPS
The part, after cutoff, can drop

through a hole in the die set to a
box directly beneath.
Overhanging stops are useful when

the press cannot be inclined, or
when the size of the die or press will
not allow part removal through the
bolster plate.
Automatic Stops
Die Design
STOCK STOPS
Cropping: An unusual stop that requires no moving mechanisms is
known as the French stop or Cropping. It operates on the principle
of cutting a shoulder in the edge of the stock strip, which acts as
stop. A strip wider than necessary is inserted into the strip channel
until it contacts the shoulder built into back gage. The first hit of the
press performs the first station operation and at the same time
punches from the side of the strip a section of metal equal to the
length of the pitch. This operation leaves a shoulder in the side of
the strip. The strip is then advanced until the strip shoulder contacts
the shoulder on the back gage on the return stroke of the ram.
Automatic Stops
Die Design
STOCK STOPS
The advantage of the cropping is its accuracy and speed of operation. It

is especially well suited to the light-gage materials that are easily
distorted when pushed or pulled against a stop pin. Its main
disadvantages are the extra cost of tooling and extra stock scrap.
Automatic Stops
Die Design
Types Pilots
Press-fit Pilots
Press-fit Pilots
Transfer dies
Spring-loaded pilots
Misfeed detector
Die Design
Press fit pilot: (A) Acorn type; (B) Flattened-point type
Die Design
Methods of retaining pilots: (A) Threaded shank; (B) Screw retained.
Die Design
Methods of retaining pilots: (C) Press fit; (D) Socket grub screw.
Die Design
Spring loaded pilot
Misfeed detector
Methods of retaining pilots: Spring with Socket grub screw.
Die Design
Strippers are of two types.
1) Fixed strippers
2) Spring-operated strippers
The primary function of either type is to strip
the work piece from a cutting or non-cutting punch or
die. A stripper that forces a part out of a die may also be
called a knockout, an inside stripper, or an ejector.
Besides its primary function, a stripper may also hold
down or clamp, position, or guide the sheet, strip, or
work piece.
Die Design
The stripper is usually of the same width and length as the die
block. In the simpler dies, the stripper may be fastened with the
same screws and dowels that fasten the die block, and the screw
heads will be counter bored into the stripper.
Fixed stripper plate
Die Design
Where spring-operated strippers are used, the force required for

stripping is 35000 times cut perimeter times the stock thickness. It
may be as high as 20 per cent of the blanking force, which will
determine the number and type of springs required. The highest of
these values should be used.
Spring-operated strippers
Die Design
Stripping Pressure Formula
L = KA
Where
Approx. values for K, as
L = Stripping force
metal thinner than 1.6 mm.
K =
cm.2
determined
by
experiment: 105 for sheet
Stripping constant, Kg /
when cut is near an edge

or near a preceding cut;
150 for other cuts in sheet
A = Area of cut surface, cm.2

(stock thickness x length of
cut)
metal thinner than 1.6 mm;

and 210 for sheet metal
more than 1.6 mm. thick.
Using of Springs for Stripping Pressure
Die Design
1)
2)
3)
4)
5)
Estimate the stripping force required according to formula.

Determine the amount of space available for spring mounting.
Select the max. allowable number of springs, which will fit into the available
space and total required force, will determine which grade of spring is required.
Determine the deflection. The required travel plus preload deflection will be the
total deflection and will determine the length of spring required to stop within
the allowable percentage of deflection limits. Allowance should be made for
punch sharpening, which will increase deflections over a period of time.
Select a spring from the lowest (greatest deflection) load rating series from the
table. It is important that the spring not be compressed beyond the specific limit
for the highest-pressure spring of corresponding length and diameter. Then if
the springs prove too light for the stripping force required, each one is
replaced with the next higher rated springs. This will provide more stripping
pressure without the need changing spring pockets, support rods and the like.
Die Design
Die Design
KNOCKOUTS
A plain inverted compound die, is of the simplest type. It consists of an actuating

plunger, knockout plate and a stop collar doweled to the plunger. Shedder D
consists of a shouldered pin backed by a spring, which is confined by setscrew
Die Design
KNOCKOUTS
In the ejection of parts positive knockouts offer the following

advantages over spring strippers where the part shape
and the die selections allow their use:
1) Automatic part disposal; the blank, ejected near the top of the
ram stroke, can be blown to the back of the press, or the press
may be inclined and the same result obtained.
2) Lower die cost; knockouts are generally of lower cost than
spring strippers.
3) Positive action; knockouts do not stick as spring strippers
occasionally do.
4) Lower pressure requirements, since there are no heavy
springs to be compressed during the ram descent.

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Chapter 5

Effect of center-of-pressure location on tool design

Control of hole and blank sizes by clearance location.

Application of the die clearance for holes of irregular shape .

* For each ton per sq. cm. of ultimate shear strength.

When cutting punch A is

If delicate punches must be

A slender piercing punch at left

If punches must protrude more

Flange width of the punch

In a large punch, push-off pins

To avoid cracking a large

Long slotting punches should be

A quill is useful for supporting

A bushing in the stripper plate

Quills need not be limited to a

Two quills are used for a

A dowel can be used to prevent

For high-speed dies, a flat on the

Light drill-rod punches are

Several punches can be set at

A illustrates a pin stop suitable

shows the method of locating the

If no scrap is left between blanks,

A design in which combinations

The part, after cutoff, can drop

Overhanging stops are useful when

The advantage of the cropping is its accuracy and speed of operation. It

Press fit pilot: (A) Acorn type; (B) Flattened-point type

Methods of retaining pilots: (A) Threaded shank; (B) Screw retained.

Spring loaded pilot

Methods of retaining pilots: Spring with Socket grub screw.

Where spring-operated strippers are used, the force required for

Approx. values for K, as

metal thinner than 1.6 mm.

experiment: 105 for sheet

when cut is near an edge

A = Area of cut surface, cm.2

metal thinner than 1.6 mm;

Using of Springs for Stripping Pressure

Using of Springs for Stripping Pressure

Estimate the stripping force required according to formula.

Using of Springs for Stripping Pressure

Using of Springs for Stripping Pressure

A plain inverted compound die, is of the simplest type. It consists of an actuating

In the ejection of parts positive knockouts offer the following

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